1,878
Views
1
CrossRef citations to date
0
Altmetric
Review Article

Field assisted additive manufacturing for polymers and metals: materials and methods

, &
Article: e2256707 | Received 11 May 2023, Accepted 02 Sep 2023, Published online: 10 Oct 2023

References

  • Berman B. 3-D printing: the new industrial revolution. Bus Horiz. 2012;55:155–162.
  • Yang J, Baker EC, Ware HO, et al. 3d printing of biomedical implants, 20180117219, 2018.
  • Sheynin D, Bovalino YM. This is what A 3D printed jet engine looks like. GE Reports. 2017. Available from: https://www.ge.com/news/reports/treat-avgeeks-inside-look-ges-3d-printed-aircraft-engine.
  • The perfect fit: carbon + adidas collaborate to upend athletic footwear, carbon. Available from: https://www.carbon3d.com/resources/case-study/adidas.
  • Matthews FL, Rawlings RD. Composite materials: engineering and science. CRC Press; 1999.
  • Gibson Lorna J. The hierarchical structure and mechanics of plant materials. J R Soc Interface. 2012;9:2749–2766.
  • Wegst UGK, Bai H, Saiz E, et al. Bioinspired structural materials. Nat Mater. 2015;14:23–36.
  • Wohlers T. Annual worldwide progress report; Wohler Associates Inc.: Fort Collins. 4 (2002).
  • Gibson RF. A review of recent research on mechanics of multifunctional composite materials and structures. Compos Struct. 2010;92:2793–2810.
  • Wu WZ, Geng P, Zhao J, et al. Manufacture and thermal deformation analysis of semicrystalline polymer polyether ether ketone by 3D printing. Mater Res Innov. 2014;18:5-12-5–16.
  • Yang C, Tian X, Li D, et al. Influence of thermal processing conditions in 3D printing on the crystallinity and mechanical properties of PEEK material. J Mater Process Technol. 2017;248:1–7.
  • Annoni M, Giberti H, Strano M. Feasibility study of an extrusion-based direct metal additive manufacturing technique. Procedia Manuf. 2016;5:916–927.
  • Gonzalez-Gutierrez J, Cano S, Schuschnigg S, et al. Additive manufacturing of metallic and ceramic components by the material extrusion of highly-filled polymers: a review and future perspectives. Materials (Basel). 2018;11:840.
  • Lieberwirth C, Harder A, Seitz H. Extrusion based additive manufacturing of metal parts. J Mech Eng Autom. 2017;7:79–83.
  • Ren L, Zhou X, Song Z, et al. Process parameter optimization of extrusion-based 3D metal printing utilizing PW–LDPE–SA binder system. Materials (Basel). 2017;10:305.
  • Lewis JA, Smay JE, Stuecker J, et al. Direct ink writing of three-dimensional ceramic structures. J Am Ceram Soc. 2006;89:3599–3609.
  • Yang H, Yang S, Chi X, et al. Fine ceramic lattices prepared by extrusion freeforming. J Biomed Mater Res B Appl Biomater. 2006;79B:116–121.
  • Van Der Klift F, Koga Y, Todoroki A, et al. 3D printing of continuous carbon fibre reinforced thermo-plastic (CFRTP) tensile test specimens. Open J Compos Mater. 2016;6:18–27.
  • Sand IDT. Thermosetting resins for use in a material extrusion process in additive manufacturing. U.S. Patent 9,707,717, (2017).
  • Chung H, Das S. Processing and properties of glass bead particulate-filled functionally graded nylon-11 composites produced by selective laser sintering. Mater Sci Eng A. 2006;437:226–234.
  • Zhong W, Li F, Zhang Z, et al. Short fiber reinforced composites for fused deposition modeling. Mater Sci Eng A. 2001;301:125–130.
  • Tekinalp HL, Kunc V, Velez-Garcia GM, et al. Highly oriented carbon fiber–polymer composites via additive manufacturing. Compos Sci Technol. 2014;105:144–150.
  • Patton ST, Chen C, Hu J, et al. Characterization of thermoplastic polyurethane (TPU) and Ag-carbon black TPU nanocomposite for potential application in additive manufacturing. Polymers (Basel). 2017;9:6.
  • Nikzad M, Masood SH, Sbarski I. Thermo-mechanical properties of a highly filled polymeric composites for fused deposition modeling. Mater Des. 2011;32:3448–3456.
  • Ne C, Elston E, Burfeindt M, et al. A fundamental study of printed ink resiliency for harsh mechanical and thermal environmental applications. Addit Manuf. 2018;20:156–163.
  • Love LJ, Kunc V, Rios O, et al. The importance of carbon fiber to polymer additive manufacturing. J Mater Res. 2014;29:1893–1898.
  • Weng Z, Wang J, Senthil T, et al. Mechanical and thermal properties of ABS/montmorillonite nanocomposites for fused deposition modeling 3D printing. Mater Des. 2016;102:276–283.
  • Hwang S, Reyes EI, Moon K, et al. Thermo-mechanical characterization of metal/polymer composite filaments and printing parameter study for fused deposition modeling in the 3D printing process. J Electron Mater. 2015;44:771–777.
  • Isakov DV, Lei Q, Castles F, et al. 3D printed anisotropic dielectric composite with meta-material features. Mater Des. 2016;93:423–430.
  • Parandoush P, Lin D. A review on additive manufacturing of polymer-fiber composites. Compos Struct. 2017;182:36–53.
  • Rajak DK, Pagar DD, Menezes PL, et al. Fiber-Reinforced polymer composites: manufacturing, properties, and applications. Polymers (Basel). 2019;11:1–4.
  • Sames WJ, List FA, Pannala S, et al. The metallurgy and processing science of metal additive manufacturing. Int Mater Rev. 2016;61:315–360.
  • Kokkinis D, Schaffner M, Studart AR. Multimaterial magnetically assisted 3D printing of composite materials. Nat Commun. 2015;6:8643.
  • LuLu T, HuShan P. Acoustic field-assisted particle patterning for smart polymer composite fabrication in stereolithography. 3D Printing Addit Manuf. 2018;5:151–159.
  • Guo Y, Batra S, Chen Y, et al. Roll to roll electric field “Z” alignment of nanoparticles from polymer solutions for manufacturing multifunctional capacitor films. ACS Appl Mater Interfaces. 2016;8:18471–18480.
  • Erb RM, Sebba DS, Lazarides AA, et al. Magnetic field induced concentration gradients 1 in magnetic nanoparticle suspensions: theory and experiment. J Appl Phys. 2008;103:063916.
  • Chen Y, Guo Y, Batra S, et al. Transparent and through thickness conductive polystyrene films using external magnetic fields for “Z” alignment of nickel nanoparticles. Nanoscale. 2015;7:14636–14642.
  • Qiang Z, Guo Y, Liu H, et al. Large-Scale roll-to-roll fabrication of ordered mesoporous materials using resol-assisted cooperative assembly. ACS Appl Mater Interfaces. 2015;7:4306–4310.
  • González-Henríquez CM, Sarabia-Vallejos MA, Rodriguez-Hernandez J. Polymers for additive manufacturing and 4D-printing: materials, methodologies, and biomedical applications. Prog Polym Sci. 2019;94:57–116.
  • Pat CW. H. U. S. vol. 4575330 (1984).
  • Al Rashid A, Ahmed W, Khalid MY, et al. Vat photopolymerization of polymers and polymer composites: processes and applications. Addit Manuf. 2021;47:102279.
  • Pawar AA, Saada G, Cooperstein I, et al. High-performance 3D printing of hydrogels by water-dispersible photoinitiator nanoparticles. Sci Adv. 2016; 2:e1501381.
  • Yin H, Ding Y, Zhai Y, et al. CrossRef CAS. 2018;9:1.
  • Nakamoto T, Kojima S. Layered thin film micro parts reinforced with aligned short fibers in laser stereolithography by applying magnetic field. J Adv Mech Des Syst Manuf. 2012;6:849–858.
  • Martin JJ, Fiore BE, Erb RM. Designing bioinspired composite reinforcement architectures via 3D magnetic printing. Nat Commun. 2015;6:8641.
  • Holmes LR, Riddick JC. Research summary of an additive manufacturing technology for the fabrication of 3D composites with tailored internal structure. JOM. 2014;66:270–274.
  • Yunus DE, Sohrabi S, He R, et al. Acoustic patterning for 3D embedded electrically conductive wire in stereolithography. J Micromech Microeng. 2017;27:045016.
  • Yang Y, Song X, Li X, et al. Recent progress in biomimetic additive manufacturing technology: from materials to functional structures. Adv Mater. 2018; 30:1706539.
  • Greenhall J, Raeymaekers B. 3D printing macroscale engineered materials using ultrasound directed self-assembly and stereolithography. Adv Mater Technol. 2017;2:1700122.
  • Lu L, Guo P, Pan Y. Magnetic-field-assisted projection stereolithography for three-dimensional printing of smart structures. J Manuf Sci Eng. 2017;139:071008.
  • Farahani RD, Dubé M, Therriault D. Three-dimensional printing of multifunctional nanocomposites: manufacturing techniques and applications. Adv Mater. 2016;28:5794–5821.
  • Ladd C, So J-H, Muth J, et al. 3D printing of free standing liquid metal microstructures. Adv Mater. 2013;25:5081–5085.
  • Mostafaei A, Kimes KA, Stevens EL, et al. Microstructural evolution and magnetic properties of binder jet additive manufactured Ni-Mn-Ga magnetic shape memory alloy foam. Acta Mater. 2017;131:482–490.
  • Ryder MA, Lados DA, Iannacchione GS, et al. Fabrication and properties of novel polymer-metal composites using fused deposition modeling. Compos Sci Technol. 2018;158:43–50.
  • Kalita SJ, Bose S, Hosick HL, et al. Development of controlled porosity polymer-ceramic composite scaffolds via fused deposition modeling. Mater Sci Eng: C. 2003;23:611–620.
  • Suwanpreecha C, Manonukul A. A review on material extrusion additive manufacturing of metal and How It compares with metal injection moulding. Metals (Basel). 2022;12:4.
  • Gunduz IE, McClain MS, Cattani P, et al. 3D printing of extremely viscous materials using ultrasonic vibrations. Addit Manuf. 2018;22:98–103.
  • Kim Y, Yuk H, Zhao R, et al. Printing ferromagnetic domains for untethered fast-transforming soft materials. Nature. 2018;558:274–279.
  • Park Y-G, An HS, Kim J-Y, et al. High-resolution, reconfigurable printing of liquid metals with three-dimensional structures. Sci Adv. 2019; 5:eaaw2844.
  • Skylar-Scott MA, Mueller J, Visser CW, et al. Voxelated soft matter via multimaterial multinozzle 3D printing. Nature. 2019;575:330–335.
  • Sriphutkiat Y, Kasetsirikul S, Ketpun D, et al. Cell alignment and accumulation using acoustic nozzle for bioprinting. Sci Rep. 2019;9:17774.
  • Li G, Zhao J, Wu W, et al. Effect of ultrasonic vibration on mechanical properties of 3D printing Non-crystalline and semi-crystalline polymers. Materials (Basel). 2018;11:4–10.
  • Bourell DL, Marcus HL, Barlow JW, et al. Selective laser sintering of metals and ceramics. Int J Powder Metall. 1992;28:369–381.
  • Yu W, Sing SL, Chua CK, et al. Influence of re-melting on surface roughness and porosity of AlSi10Mg parts fabricated by selective laser melting. J Alloys Compd. 2019;792:574–581.
  • Ding Z, Yuan C, Peng X, et al. Direct 4D printing via active composite materials. Sci Adv. 2017; 3:e1602890.
  • de Marco C, Pané S, Nelson BJ. 4D printing and robotics. Sci Rob. 2018;3:eaau0449.
  • Sydney Gladman A, Matsumoto EA, Nuzzo RG, et al. Biomimetic 4D printing. Nat Mater. 2016;15:413–418.
  • Caputo MP, Berkowitz AE, Armstrong A, et al. 4D printing of net shape parts made from Ni-Mn-Ga magnetic shape-memory alloys. Addit Manuf. 2018;21:579–588.
  • Scheithauer U, Weingarten S, Johne R, et al. Ceramic-Based 4D components: additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by thermoplastic 3D printing (T3DP). Materials (Basel). 2017;10:1–6.
  • Liu G, Zhao Y, Wu G, et al. Origami and 4D printing of elastomer-derived ceramic structures. Sci Adv. 2018; 4:eaat0641.
  • Zhao H, Li K, Han M, et al. Buckling and twisting of advanced materials into morphable 3D mesostructures. Proc Natl Acad Sci USA. 2019;116:13239–13248.
  • Momeni F, Liu X, Ni J. A review of 4D printing. Mater Des. 2017;122:42–79.
  • Huang L, Jiang R, Wu J, et al. Ultrafast digital printing toward 4D shape changing materials. Adv Mater. 2017;29:1605390.
  • Zhu P, Yang W, Wang R, et al. 4D printing of complex structures with a fast response time to magnetic stimulus. ACS Appl Mater Interfaces. 2018;10:36435–36442.
  • Lui YS, Sow WT, Tan LP, et al. 4D printing and stimuli-responsive materials in biomedical aspects. Acta Biomater. 2019;92:19–36.
  • Hendrikson WJ, Rouwkema J, Clementi F, et al. Towards 4D printed scaffolds for tissue engineering: exploiting 3D shape memory polymers to deliver time-controlled stimulus on cultured cells. Biofabrication. 2017;9:031001.
  • Miao S, Zhu W, Castro NJ, et al. 4D printing smart biomedical scaffolds with novel soybean oil epoxidized acrylate. Sci Rep. 2016;6:27226.
  • Kuang X, Chen K, Dunn CK, et al. 3D printing of highly stretchable, shape-memory, and self-healing elastomer toward novel 4D printing. ACS Appl Mater Interfaces. 2018;10:7381–7388.
  • Han D, Yang C, Fang NX, et al. Rapid multi-material 3D printing with projection micro-stereolithography using dynamic fluidic control. Addit Manuf. 2019;27:606–615.
  • Collino RR, Ray TR, Fleming RC, et al. Begley,M.R.deposition of ordered two-phase materials using microfluidic print nozzles with acoustic focusing. Extrem Mech Lett. 2016;8:96–106.
  • Dubinin ON, Chernodubov DA, Kuzminova YO, et al. Gradient soft magnetic materials produced by additive manufacturing from non-magnetic powders. J Mater Process Technol. 2022;300:117393.
  • Suppan M, Huber C, Mathauer K, et al. In-situ alignment of 3D printed anisotropic hard magnets. Sci Rep. 2022;12:17590.
  • Roy M, Tran P, Dickens T, et al. Effects of geometry constraints and fiber orientation in field assisted extrusion-based processing. Addit Manuf. 2020;32:101022.
  • Henderson L, Zamora S, Ahmed TN, et al. Altering magnetic properties of iron filament PLA using magnetic field assisted additive manufacturing (MFAAM). J Magn Magn Mater. 2021;538:168320.
  • Safaee S, Chen RK. Development of a design and characterization framework for fabrication of functionally graded materials using magnetic field-assisted digital light processing stereolithography. J Manuf Process. 2021;67:314–324.
  • Joyee EB, Pan Y. Investigation of a magnetic-field-assisted stereolithography process for printing functional part with graded materials. 2020 International Symposium on Flexible Automation, 2020 July 8–9; ASME; 2020. doi:10.1115/ISFA2020-9650
  • Joralmon D, Amonoo E, Zhu Y, et al. Magnetic field-assisted 3D printing of limpet teeth inspired polymer matrix composite with compression reinforcement. ASME 2021 16th International Manufacturing Science and Engineering Conference, 2021 June 21–25. doi:10.1115/MSEC2021-61050.
  • Al-Milaji KN, Hadimani RL, Gupta S, et al. Inkjet printing of magnetic particles toward anisotropic magnetic properties. Sci Rep. 2019;9:16261.
  • Zhao R, Chen C, Shuai S, et al. Enhanced mechanical properties of Ti6Al4 V alloy fabricated by laser additive manufacturing under static magnetic field. Mater Res Lett. 2022;10:530–538.
  • Khan MY, Rao PS, Pabla BS. An experimental study on magnetic field-assisted-EDM process for inconel-625. Adv Mater Process Technol. 2022: 1–27. doi:10.1080/2374068x.2022.2036450
  • Zhou H, Song C, Yang Y, et al. The microstructure and properties evolution of SS316L fabricated by magnetic field-assisted laser powder bed fusion. Mater Sci Eng A. 2022;845:143216.
  • Li G, Wang Z, Yao L, et al. Concentration mixing and melt pool solidification behavior during the magnetic field assisted laser cladding of Fe-Cr-based alloy on 45 steel surface. Surf Coat Technol. 2022;445:128732.
  • Wang J, Wang Y, Shi J, et al. Effect of external magnetic field on the microstructure of 316L stainless steel fabricated by directed energy deposition. Volume 2B: Adv Manuf. 2019. doi:10.1115/imece2019-12122
  • Wang Y, Chen X, Shen Q, et al. Effect of magnetic field on the microstructure and mechanical properties of inconel 625 superalloy fabricated by wire arc additive manufacturing. J Manuf Process. 2021;64:10–19.
  • Wu P-Y, Hirtler M, Bambach M, et al. Effects of build- and scan-directions on magnetic field-assisted finishing of 316L stainless steel disks produced with selective laser melting. CIRP J Manuf Sci Technol. 2020;31:583–594.
  • Zhao W, Wei Y, Zhang X, et al. Comparative investigation of wire arc additive manufacturing of Al-5%Mg alloy with and without external alternating magnetic field. Int J Adv Manuf Technol. 2022;119:2571–2587.
  • Holmes J. Micro-Composite fabrication via field-aided laminar composite (FALCom) processing. Adelphi (MD): US Army Research Laboratory; 2012.
  • Plog J, Jiang Y, Pan Y, et al. Electrostatically-assisted direct ink writing for additive manufacturing. Addit Manuf. 2021;39:101644.
  • Duncan JL, Schultz J, Barlow Z, et al. Introducing electric field fabrication: a method of additive manufacturing via liquid dielectrophoresis. Addit Manuf Lett. 2023;4:100107.
  • Chen R, Bratten A, Rittenhouse J, et al. Additive manufacturing of complexly shaped SiC with high density via extrusion-based technique – effects of slurry thixotropic behavior and 3D printing parameters. Ceram Int. 2022;48:28444–28454.
  • Bratten A, Chen R, Rittenhouse J, et al. Improved additive manufacturing of silicon carbide parts via pressureless electric-field assisted sintering. Int J Appl Ceram Technol. 2022. doi:10.1111/ijac.14105
  • Li H, Zi D, Zhu X, et al. Electric field driven printing of repeatable random metal meshes for flexible transparent electrodes. Opt Laser Technol. 2023;157:108730.
  • Zhang H, Zhu X, Zhou J, et al. Microscale hybrid additive manufacturing of ultra-fine, embedded Cu/Ag(shell)–P4VP(core) grid for flexible transparent electrodes. Adv Mater Technol. 2023;8:2201580.
  • Li Z, Li H, Zhu X, et al. Directly printed embedded metal mesh for flexible transparent electrode via liquid substrate electric-field-driven Jet. Adv Sci. 2022;9:2105331.
  • Huang J, Liu G, Yu X, et al. Microstructure regulation of titanium alloy functionally gradient materials fabricated by alternating current assisted wire arc additive manufacturing. Mater Des. 2022;218:110731.
  • Zhang T, Zhou J, Lv J, et al. A novel hybrid ultrasonic and electromagnetic field assisted laser cladding: experimental study and synergistic effects. J Mater Process Technol. 2022;307:117658.
  • Ouyang W, Xu Z, Liu Y, et al. Effect of non-contact electrostatic field on controlling the microstructure of 316L during laser additive manufacturing process. Other Conferences. 2020:11717.
  • Kaldre I, Milgravis M, Milgrāvis M, et al. Electromagnetic processing during directional solidification of particle-strengthened aluminum alloys for additive manufacturing. Proceedings of The 1st international electronic conference on metallurgy and metals 3, 19; 2021.
  • Song Y, Xu L, Xu L, et al. Fabrication and characterization of magnetic nanocomposites by electric fields assisted electrospinning. Therm Sci. 2019;23:2365–2372.
  • Lichade KM, Pan Y. Acoustic field-assisted two-photon polymerization process. J Manuf Sci Eng-Trans ASME. 2021;143:104501.
  • Liu C, Pandit PP, Parsons C, et al. Acoustic field-assisted inkjet-based additive manufacturing of carbon fiber-reinforced polydimethylsiloxane composites. J Manuf Process. 2022;80:87–94.
  • Lichade KM, Hu S, Hu S, et al. Two-photon polymerization of anisotropic composites using acoustic streaming. Manuf Lett. 2021. doi:10.1016/j.mfglet.2021.09.001
  • Lichade KM, Pan Y. Fast and simple fabrication of multimaterial hierarchical surfaces using acoustic assembly photopolymerization (AAP). Adv Mater Interfaces. 2023;10:2201981.
  • Lichade KM, Pan Y. 3D printing of anisotropic multimaterial structures using acoustic streaming-assisted Two-photon polymerization. Manuf Lett. 2022;33:644–655.
  • Niu F, Li Y, Song C, et al. Microstructure and wear resistance of TiCp/Ti6Al4 V composite coatings by follow-Up ultrasonic-assisted laser additive manufacturing. Coatings. 2022;12:986–986.
  • Yuan D, Shao S, Guo C, et al. Grain refining of Ti-6Al-4V alloy fabricated by laser and wire additive manufacturing assisted with ultrasonic vibration. Ultrason Sonochem. 2021;73:105472.
  • Zhang YF, Li Z, Li H, et al. Fractal-Based stretchable circuits via electric-field-driven microscale 3D printing for localized heating of shape memory polymers in 4D printing. ACS Appl Mater Interfaces. 2021;13:41414–41423.
  • Podstawczyk D, Nizioł M, Szymczyk P, et al. 3D printed stimuli-responsive magnetic nanoparticle embedded alginate-methylcellulose hydrogel actuators. Addit Manuf. 2020;34:101275.
  • Joyee EB, Pan Y. Additive manufacturing of multi-material soft robot for on-demand drug delivery applications. J Manuf Process. 2020;56:1178–1184.
  • Sola A, Trinchi A, Hill AJ. Self-assembly meets additive manufacturing: bridging the gap between nanoscale arrangement of matter and macroscale fabrication. Smart Mater Manuf. 2023;1:100013.
  • Ryan KR, Down MP, Hurst NJ, et al. Additive manufacturing (3D printing) of electrically conductive polymers and polymer nanocomposites and their applications. eScience. 2022;2:365–381.
  • Decker B, Gan Y. Electric field-assisted additive manufacturing polyaniline based composites for thermoelectric energy conversion. J Manuf Sci Eng. 2015;137:024504.
  • Zhang X, Zhang H, Li D, et al. Highly thermally conductive and electrically insulating polydimethylsiloxane composites prepared by ultrasonic-assisted forced infiltration for thermal management applications. Compos Part B: Eng. 2021;224:109207.
  • Chung HS, Hogg R. The effect of Brownian motion on particle size analysis by sedimentation. Powder Technol. 1985;41:211–216.
  • Kyrylyuk AV, Philipse AP. Effect of particle shape on the random packing density of amorphous solids. Phys Status Solidi (A). 2011;208:2299–2302.
  • Foernzler E, Martin A, Banker G. The effect of thixotropy on suspension stability. J Am Pharm Assoc. 2006;49:249–252.
  • Sodipo BK, Aziz AA. Recent advances in synthesis and surface modification of superparamagnetic iron oxide nanoparticles with silica. J Magn Magn Mater. 2016;416:275–291.
  • Hosseini S, Patel D, Ein-Mozaffari F, et al. Study of solid–liquid mixing in agitated tanks through electrical resistance tomography. Chem Eng Sci. 2010;65:1374–1384.
  • Saccone MA, Gallivan RA, Narita K, et al. Additive manufacturing of micro-architected metals via hydrogel infusion. Nature. 2022;612:685–690.
  • Safaee S, Schock M, Joyee EB, et al. Field-assisted additive manufacturing of polymeric composites. Addit Manuf. 2022;51:102642.
  • Sing SL, Kuo C-N, Shih C-T, et al. Perspectives of using machine learning in laser powder bed fusion for metal additive manufacturing. Virtual Phys Prototyp. 2021;16:372–386.
  • Qin J, et al. Research and application of machine learning for additive manufacturing. Addit Manuf. 2022;52:102691.
  • Hu Y, Hu Y. Recent progress in field-assisted additive manufacturing: materials, methodologies, and applications. Mater Horiz. 2021;8:885–911.